Peluang & Tantangan :

SUSTAINABLE
MANUFACTURING
Studi kasus : Industri Semen

Harwin Saptoadi
Department of Mechanical and Industrial
Engineering
Universitas Gadjah Mada
 SUSTAINABILITY

INTRODUCTION
• Industrialization is a must for all countries in
order to be more prosperous.
• Higher productivity promises higher profit for its
manufacturers.
• However, it requires more raw materials and
more energy, and discharges more wastes.
• Uncontrolled manufacturing will diminish natural
resources and heavily pollute the environment.
• Environmentalists & people get angry.
 SUSTAINABILITY

INTRODUCTION
• Manufacturing will terminate without natural
resources and buyers.
• Less profit for longer period is preferable than
high profit but for limited time.
• Sustainability in manufacturing : Continuous and
long term production process considering pros-
perity of the next generations.
 SUSTAINABILITY

INTRODUCTION
• According to a survey* among production and
manufacturing managers in a cement factory, the
following KPIs have substantial importance for
sustainable manufacturing:
• Material cost.
• Energy consumption.
• Raw material substitution.
• Fuel consumption.
• Air emission.
• Etc.
* Amrina & Vilsi, 2015; https://doi.org/10.1016/j.procir.2014.07.173
 SUSTAINABILITY

RAW MATERIALS
• Required raw materials (sent to raw mills): Lime
stone, Clay, Silica sand, Copper slag, etc.
• Required raw materials (sent to cement mills):
Gypsum, Trass, Fly ash, etc.
• The use of non-renewable raw materials (e.g.
Lime stone, Clay, Silica sand) must be minimized to
let them available in longer time. Usually they are
substituted by side products / wastes or other al-
ternative materials.
 SUSTAINABILITY

RAW MATERIALS
• Alternative (sometimes even hazardous and toxic)
materials are utilized, e.g. Fly ash, Bottom ash,
Copper slag, Drilling cement cutting, Sewage
sludge, Oil sludge, Foundry sand, Mill scale.
• High temperatures inside rotary kilns (up to 1450
oC), so called co-processing, are able to convert

those alternative materials into oxide compounds,

which improve the cement quality, but still
environmental friendly.
 SUSTAINABILITY

RAW MATERIALS
• Cooperations are established with external com-
panies to provide those alternative (raw) materials.
• The indicator of material efficiency is Material
intensity (ton of total raw material per ton of
produced cement). It should continuously decrease.
 MATERIAL INTENSITY
www.semenpadang.co.id/file/ar_2017/sr2017.pdf

Year 2013 2014 2015 2016 2017

Total raw materials 17.40 17.61 10.54 9.71 10.26

(million ton)

Cement production 6.61 6.67 6.89 6.46 7.44

(million ton)

Material intensity 2.63 2.64 1.53 1.50 1.43

 SUSTAINABILITY

ENERGY CONSUMPTION
• 2 types of consumed energy:
• Primary : from coal and oil / diesel fuel, for kiln
fuel, mining, transport.
• Secondary : electricity, for production support,
machineries, administration, lighting.
• Most (thermal) energy is consumed in rotary kilns
for producing clinkers from lime stone, clay and
other additives.
 SUSTAINABILITY

ENERGY CONSUMPTION
• Since the portion of energy cost in cement pro-
duction is high (38% - 41%), even small energy
savings will be substantially beneficial.
• Efforts for improvement of energy efficiency is ex-
tremely demanded.
Examples:
•Wet process was replaced by dry process due to
the energy efficiency reason.
 SUSTAINABILITY

ENERGY CONSUMPTION
Other examples of energy efficiency:
• Upgrading of machineries, e.g. Grinder (roller
mill), Classifier, Dry kiln with preheater & precal-
ciner.
• Check up and maintenance of machineries.
• Seeking for better product formulation by redu-
cing clinker portion (78% - 86%).
• WHRPG (waste heat recovery power generation).
 SUSTAINABILITY

ENERGY CONSUMPTION
Other examples of energy efficiency:
• Installation of Photovoltaic Solar Cells in free
areas.
• Replacement of inefficient lamps.
• Increasing use of alternative, mostly renewable
fuels.
• The indicator of energy efficiency is Energy
intensity (GJ of total consumed energy per ton of
cement). It should continuously decrease.
 ENERGY INTENSITY
www.indocement.co.id/v5/IndocementContent/Laporan Keberlanjutan 2018_INTP_290419.pdf

Year 2015 2016 2017 2018

Total energy
consumption 49.42 46.68 50.47 52.79
(million GJ)

Cement production 17.24 16.35 17.14 18.1

(million ton)

Energy intensity 2.87 2.85 2.95 2.91

(GJ/ton)
ENERGY INTENSITY
EECCHI, DitJen EBTKE, KESDM, 2011
 SUSTAINABILITY

MATERIAL SUBSTITUTION
• Considering the economical and environmental
reasons, expensive and virgin non-renewable mate-
rials should be substituted without degrading pro-
duct quality.
• They include raw materials for producing clinkers
and fuels for energizing factory operation.
• The substituting materials are selected because
they are cheaper, renewable, wastes (even hazar-
dous and toxic), or environmental friendlier.
 SUSTAINABILITY

MATERIAL SUBSTITUTION
Examples :
• Side products from iron & steel industries, e.g. fo-
undry sand, mill scale, slag, for producing clinkers.
• Wastes from coal-fired electric power plants, e.g.
fly ash (to cement mills) and bottom ash (to raw
mills).
• Alternative fuels, e.g. TDF (Tire-derived Fuel), RDF
(Municipal waste), biomass waste, sludge oil, paint
sludge, contaminated goods.
• Use of lower calorific coal.
 SUSTAINABILITY

MATERIAL SUBSTITUTION
Examples :
• The use of biomass wastes (rice husk, oil palm shell, saw
dust) as alternative fuels, and the utilization of solid
wastes (bottom ash, copper slag, fly ash, granulated blast
furnace slag) is a part of a CDM project.
• Many CER have been published by UNFCCC and the
cement company can get money from it.
• Some companies have permission from Ministry of
Environment to manage and process hazardous and toxic
wastes.
 DATA ON MATERIAL SUBSTITUTION
www.sementonasa.co.id/dokumen/SR 2016 (English).pdf

Year 2013 2014 2015 2016

Cement production 6.12 6.06 5.96
(million ton)
Biomass (ton) 35,860 12,550 3,030
Sludge oil (ton) 0 0 139,840
Fly ash (ton) 18,549 29,125 32,388
Bottom ash (ton) 3,638 4,936 8,476
Copper slag (ton) 19,439 19,646 21,209
Total raw materials 8.78 9.32 8.99 10.20
(million ton)
Alternative raw 1.07 1.22 1.25 1.06
materials (million ton)
Percentage (%) 12.3 13.1 13.9 10.4
 SUSTAINABILITY

AIR EMISSIONS
• Emissions are from raw material mining, cement
production, and transportation.
• Several emitted gaseous substances are NOx, SOx,
CO and CO2. They are either GHG or toxic.
• NOx is mostly thermal NOx formed at high com-
bustion temperature.
• SOx is produced because the fuel contains sul-
phur.
• CO is an indicator of incomplete combustion, due
to lack of air or insufficient temperature.
 SUSTAINABILITY

AIR EMISSIONS
• Great attention is paid on CO2 because it is one of
GHG which cause GW & CC.
• All are monitored real time with CEMS.
• The world is concerned about GW & CC. One of
the actions is CDM – CER – UNFCCC.
• One of the solutions is energy efficiency.
 SUSTAINABILITY

AIR EMISSIONS
• There is also solid particulate in the air emission,
called CKD (cement kiln dust).
• CKD is captured by ESP and baghouse filters, then
returned to production system or directly sold, be-
cause actually it is a valuable product.
• Previously CKD was dumped in landfills.
• One of the solutions is green belt as a natural
filter, that is also able to catch CO2.
 DATA ON AIR EMISSION
www.sementonasa.co.id/dokumen/SR 2016 (English).pdf

Quality 2014 2015 2016

Standard

NOx (mg/Nm3) 1000 17.73 4.38

SOx (mg/Nm3) 800 20.29 5.88
Particulate (mg/Nm3) 80 30.6 60.88
Dust at work environment
(mg/Nm3) 10 1.08 1.16 0.89
Direct GHG emission
(ton CO2 eq.) 4,770,557 4,624,582 4,243,158
 DILEMMA OF ECOCARS

CONCLUSIONS
1. The use of non-renewable raw materials must
be minimized to let them available in longer time.
Usually they are substituted by side products or
other alternative materials, even toxic and
hazardous wastes.
2. The substituting materials are selected because
they are cheaper, renewable, wastes, or environ-
mental friendlier.
 DILEMMA OF ECOCARS

CONCLUSIONS
3. Material intensity and Energy intensity should
be continuously decreased.
4. Air emission is still under the environmental
limits, however they should be kept minimum,
especially GHG and CKD.
THANK YOU VERY MUCH
FOR
YOUR ATTENTION